EricRS

Not sure if it's in the right place. Mods can move it if it's not.

Tackled this today myself.

I noticed a small water leak on Saturday coming from somewhere near the right side of the engine as you look at it. I traced it back to its highest point and it turned out to be coming from the side of the thermostat housing. (common problem).

I ordered the following parts from Ford to rectify the problem.

1 x Thermostat housing. (comes with the rubber ring swasher).

1 x Thermostat. (Didn't come with the rubber seal, had to use the old one that was in good nick thank God).

1 x expansion bottle (yellow cap).

How I did it:

1. Position the car over a shore in the street or a bucket to catch the water as it empties from thermostat housing.

2. Remove Yellow cap from expansion bottle and trough in the bin.

3. Remove the small hose from the top of the thermostat housing.

4. Remove two front hose from the thermostat housing and then the hose from the rear.

5. Remove the three 10mm bolts and take the housing off. Open the thermostat cap (star shaped tool needed for this) if you need to reuse the rubber seal for the new thermostat but I suggest you buy a new one when ordering the parts.

6. Put the rubber seal on the new thermostat and but it in position in the new thermostat housing. There's a nipple on it that seats in place so you know it's in right. Then fit the new thermostat cap and tighten the three screws.

7. Size up the housing so all three bolt holes are in line with their opposite holes and refit the 3 bolts tightening them a little at a time working your way around all three. In sure the rubber seal is seated correctly before you size it up. Make sure their tight but not to tight.

8. Reconnect the 3 larger hoses. The one at the rear and the two at the front.

9. At this stage leave the small hose off. Pure coolant/anti freeze into the expansion bottle until water starts to come out of the top of the housing where the little hose fits on. Once this happens reconnect the small hose. Star your car and turn the heating on full blast.

10. Pour coolant/ anti freeze into the expansion bottle until the max level is reached then stop. Observe the level and keep topping up when ever the level changes. I pressed the top large hose on the housing a few time to make sure there was no air locks. (saw a lad do this once, not sure if it makes any difference but it cann't hurt). Once the max level no longer changes fit you new yellow cap onto the expansion bottle and tighten.

11. While the engine is still running and the pressure with everything closed off reaches where it should be check for leaks and make sure all clamps etc are tight.

12. Bring the RS for a spin and then recheck everything.

Jobs OXO.

Hope this helps.

big eck

Good guide mate as its a common problem.

How much did all the parts cost???

EricRS

133 euro is what it cost me due to a discount. Not sure how much it would be for the UK. I would imagine a bit cheaper due to our VAT rate.

CarParts Express

there u go...
http://www.carpartsexpress.co.uk/pro...ents=&P_ID=500

EricRS

Ah thats what the thermostat cap is. (Focus rs water outlet)

So the parts where:

1 x Focus rs thermostat housing.

1 x Focus RS Thermostat.

1 x Focus rs water outlet.

1x yellow cap (expansion bottle).